Spacer insert in a container



oct. 22, 19631` Filed sept. 27., 1961 oct. 22, 1963 R. H. swam-:RT 3,107,780

SPACER INSERT 1N A CONTAINER Filed Sept. 27, 1961 2 Sheets-Sheet 2 United States Patent O 3,l07,73tl SPACER INSERT IN A CGNTAENER Robert H. Stuckert, Milwaukee, Wis., assigner to Crown Zellerhach Corporation, San Francisco, Calif., a corporation of Nevada Filed Sept. 27, 196i, Ser. No. 141,173 2 Claims. (Cl. 20S- 45) This invention relates to a spacer insert adapted to position and protect an article in a shipping container. More particularly, the invention relates to a container insert, formed from a single sheet of bendable material, such as brehoard, corrugated breboard or the like, and serving to positively position an article in spaced relation to the side Walls and one end closure of the shipping container.

The invention provides a container insert that may be formed by the Simple folding of a single blank of material. Nevertheless, the insert is eminently satisfactory for the packaging of tall, heavy articles such as Water heaters which must be stabilized in spaced relation within the confines of a container and protected from shock and abrasion.

The insert may be preassembled and positioned over and in engagement with an article in a container prior to the final closure of the top of the container. An important feature of the invention is that the insert circumferentially engages the article -in the container about a determined end portion thereof Iand provides a multiple thickness of the material forming the insert in flatwise relation to paired diametrically opposite portions of the article to positively position and cushion the article. There are .further provided top end panels hingedly connected to an interior portion to the container insert and serving to cushion and vertically space the article in the container from the final closure thereof. These top end panels further serve to maintain the insert in precise disposition in the container so that the article in the container is circumferentially engaged about a precise trans- Verse section thereof.

Other objects and advantages of this invention will be apparent to those skilled in the art upon a full and complete understanding of the construction of the container insert. The accompanying drawings illustrate an ernbodiment of the invention and form a part of the specification. Like numerals and symbols therein appearing refer to like parts wherever they occur.

In the drawings:

FIG. l is a plan View illustrating the blank from which an embodiment of the container insert is formed.

FIG. 2 is a cross sectional view of double Wall corrugated board, the preferred material for constructing the container insert.

FIG. 3 is a perspective view of .a container insert fully erected and ready for insertion in a container.

FIG. 4 is a cross sectional view through line 4 4 of FIG. 3.

FIG. 5 is a cross sectional view of the insert in the container engagin-g and protecting a Water heater therein.

FIG. 6 is a cross sectional view similar to FIG. 4 but showing a modified insert providing additional top cushioning and spacing.

PIG. 7 is a perspective View of a container insert in erecting condition with the top panels fan folded to form spacing bars.

FIG. 8 is a cross sectional view of a spacing bar through line 8-8 in FIG. 7.

Por purposes of simplicity and clarity of description the following description will particularly set forth a description of an embodiment of the invention particularly adapted for packaging water heaters which is illustrative o-f the capability of the simple and economical insert ICC to position and protect tall, heavy articles in a container. For this particular commercial embodiment of the invention it has been `found that doublewall corrugated board, shown in cross section view FIG. 2, provides the desired strength and cushioning characteristics, but it is evident that for smaller or lighter .articles ordinary doubleface corrugated board or iibreboard may be used with facility.

The blank for the insert, top view shown in FIG. l, may he conveniently formed by die-cutting a at sheet and comprises a base panel l0 which conforms closely to a transverse section of the container and has outer edges dened by flap scores lll. The flap scores lll further senve as the hinge connection of the spacer aps l2 which are further sub-divided into an outer flap 13, intermediate flap i4- and inner flap l5.

In the base panel lll there is an interior edge 16 spaced from the base panel edges il and adapted to conform closely to the outer perimeter of a transverse section of the article to be placed in the container. A pair of top panels 17 are each Ifoldably connected to opposite portions of the interior edge lo by connecting Webs TLS. The connecting web 4hinge lines are determined by score lines 19, represented as dotted lines in the drawing, which may be either deeply impressed or perforated in the die cutting operation. In addition the connecting webs are provided with a contour `score line 2li which may he desirable when rthe container insert is used for packaging a Water heater having substantially rounded top edges so that the connecting webs and top panels f7 may conform closely to the contours of the Water heater.

Tabs 22 are hingedly connected to the interior edge lo by score lines 23 but are otherwise dened by free edges 24 so that they are independent yof each other and of the top panels 17.

In the spacer flaps 12 the outer flap i3 and intermediate flap 14 are lhingedly connected about their adjacent edges indicated by line 26. The intermediate flap and inner llap are in turn liingedly connected by score line 27. Since the blank A is constructed from double- Wall board, as is shown in cross section in FIG. 2, when the insert is to be used for packaging Water heaters or comparable tall heavy articles, the folding of the spacer ilaps l2 may be implemented by the use of particular fold connections. -For example, the line of hinge connection along line 26 is preferably provided with spaced apart hinge webs 2.3 which are deiined by transverse slit edges 29. The outer flap 13 and intermediate flap 14 are otherwise separated by a slit along line 26. The intermediate spacer flap 14 and inner spacer flap l5 are hingedly connected by the beforementioned score line 27 which is preferably a cut score being partially severed in the die cutting operation, but leaving at least the bottom facing liner of the blank intact.

It will be noted further in respect to the rspacer flaps that the outer flap i3 is substantially cotermino-us in width with the respective edges of the base panel Whereas the intermediate flap 14 and inner flap 15 are shortened in Width in respect thereto for reasons which will be hereinafter described in regard to the erected container inserat.

The `doublevvall board for forming the container shown in FIG. 2 in cross sectional view is comprised of a facing sheet '31, a second facing sheet 32, and an intermediate facing sheet 33 which are each separated lby and secured to corrugated sheets 34. This type of corrugated board provides great structural strength and, in addition, provides the `desired cushioning qualities land thickness for adequate spacing of the Water heater from the Walls and end closure of the enclosing container.

To erect the ycontainer linsert to operative condition as shown in FIG. 3, the spacer flaps l2 are successively folded to for-rn multiple ply spacer Walls 36 in normal aros/:so

relation to the base panel ll) in FIG. l and overlying the marginal edge portions 37 of the base panel intervening the ilap scores l1 land the interior edge ld, which may be deiined by the connecting web score lines i9 or tab score lines 2.3. The folding of the spacer llaps may be accomplished by folding the successive hinge connections or score lines in an `alternating fashion lto form fan folds or they may be folded successively in one direction to roll-up the spacer wall. While the spacer walls may Abe `formed of a varying number of plies, it has been found desirable to form a three ply wall, as shown in the drawings, to attain the desired spacing about a water heater in a conrainer when the container spacer insert is constructed of double Wall board. It is to be noted that the side edges 37 of the intermediate and inner spacer flaps, 14 and i5, are recessed ina suitable manner to permit the disposition of `the spacer walls 36 over the base panel lil.

In FIG. 4 is illustrated a cross sectional view through line `4-4 of FIG. 3. Thus it may be observed that the spacer -flaps l2 are disposed overlying and in norm-al relation to the marginal edge portion 37 of the base panel as before stated. ln this view the spacer flaps l2 are fan 'folded 'about the hinge webs 2B and a cut Iscore line 27. This construction provides ease of folding of the heavy double-wall board and reduces the springiness that would be encountered with conventional depressed score lines. A further yadvantage of -this construction is that it lends itself lto die cutting the lblank from one side with a relatively simple die.

The spacer aps l2 `are supplemented in this cross sectional view by the connecting webs 18 to form the complete elective thickness Iof the spacer wall 36. In this view, the connecting webs l are scored at 20 to adapt the connecting webs to the contour of a rounded edge water heater. The top panels 17 extend inwardly in a generally horizontal direction from their fold connection i9 with Ithe connecting webs.

The spacer insert is shown positioned over the top end of a water heater `and enclosed in a container 35 in FIG. 5. The spacer inse-rt is show-n in the same cross sectional view Ias in FIG. 4. The container 35 may be of any suitable conventional construction as for example the container shown in the Beaman Patent No. 2,214,220, Multi-Wall Bull; Pak Shipping Containers or a slotted carton having foldably connected Walls in tubular relation and ap closures on the ends. A slotted carto-n is illustrated in the drawings.

The spacer insert is positioned over the water heaterV prior to the closure yof the container top closure 39. lt may be lseen that the spacer flaps l2 and the connecting webs d8 provide a positive spacing of the Water heater top side edges from the container walls and in addition rthe top panels 17 overlie the water heater and provide positive spacing between said heater and the container top closure. e insert is frictionally retained in position prior to positioning the end closure of the container, but thereafter lthe idisposition of the insert in the container is positively restrained against downward movement by the engagement or" the top panels between the heater and the container closure. Further the spacer aps being in edgewise abutment with the inner surface of the container closure insures that :the spacer wall 36 is iixedly retained about the desired end portion of the water heater. Suitable bottom spacer means SS is provided in the container to xedly position the Water heater supporting legs in the container in accordance with cornrnon practice.

It may be desirable, particularly for water heaters and other like heavy articles, to provide additional spacing between the top end of the article in the container and the container closure. To ellect this result the spacer insert may be suitably modified to provide additional spacer means by folding the top panels 17 into spacing bars di) of a suitable thickness. This may be uaccomplished by transversely scoring said` top panel along parallel spaced apart lines of fold and rolling up said scored top panel portions as shown in FIG. 6. FIG. 6 is a cross sectional View similar so FIG. 4 but shows the top panel 3.7 folded about ytransverse scores il to provide the multiple thickness spacing bars di?. This construction will provide two spaced apart preferably parallel spacing bars 40 which adequately cushion and space the Water `heater top end from the container top end closure.

An alternative construction which lmay provide Spacing bars of lgreater vertical height is illustrated in FIG. 7 which is a perspective view of a container insert in erected condition. Hme the top panel 17 is suitably scored along longitudinal spaced apa-rt lines of weakness i2 to denne panel portions 43 which are fan folded into flatwise rela- :tion to each other yand in normal relation to the water heater top end and container closure.

ln FIG. `8 is illustrated -a cross sectional view through line S-S of FIG. 7. In this view the spacing bar 40 is formed from a top panel 17 by fan folding the panel portions yi3 about the parallel spaced apart lines of weakness 42. The spacing bar 4i) is spaced from the base panel l@ by 'the connecting web 1S. ln this view, the spacing bar is slightly expanded for purpose of clarity, but it is understood that it will normally be desirable to have the panel portions 43 in compact llatwise relation to each other. The panel portions -43 are folded and disposed in `overlying and normal relation to a center portion of the top panel 17 which is in alignment with the connecting web iS.

It will generally be found convenient to secure the rolled or fan folded spacing bars 4t) by the use of suitable adhesive or tape :to maintain the panel portions .in contacting llatwise relation during packing and shipment of the container.

The spacer' insert l-for a container, as described in the preceding, provides a simple one-piece integral insert for a container which cushions and positively spaces a water heater from the walls and top end closure of an enclosing container. This result is attained, even though the spacer insert is formed from a simple rectangular blank, as the blank is suitably cut and scored to permit the folding of the panels and parts thereof to provide multiple thicknesses of the material between the water heater and the adjacent container parts. Thus the dependence on critical or elaborate constructions heretofore known in the art is avoided andy the simple spacer insert is capable of maintaining its effectiveness under the severe stresses encountered in handling and shipment of water heaters in containers.

While, in the View shown, the spacer bars are formed from the generally semicircular top panels 17 for uniformity in the several drawings, it is an obvious expedient to form the top panels i7 in a substantially rectangular form. This may be accomplished by reducing certain of the tabs 22 which are not in contacting relation with the spacer walls 36. By this means the spacing bars -rnay be oi substantially uniform character throughout their length.

Since the top panels l'' or spacing bars 4G formed therefrom are spaced apart in the erected condition of the spacer insert, adequate provision may be made for protruding pipe connectors or nipples extending from the top end of the water heater. When such protrusions extend to a substantial height `above the heater the fan folded form of spacing bars illustrated in FlGS. 7 and 8 is preferred as the necessarily limited amount of material available in the -top panel i7 may be utilized to form a spacing bar of substantial vertical height. Obviously because of the limited amount of material it will be necessary to vary the number of plies or panel portions 43 in accordance with the height desired.

lt is to ybe understood that the invention may be susceptible of other modified forms and that the embodiments erein described are illustrative and not restrictive. All such modifications which are similar or equivalent hereto come equally within the scope of the claims next appearing.

I claim:

l. ln a container having vertical walls in polygonal formation and a top closure enclosing -an article of manufacture, a spacer insert for positioning over and in circumferential engagement with the article to laterally space the article from the vertical side walls of the container, said insert comprising a unitary :blank having a base panel horizontally disposed about a `transverse section of the said article and having an interior edge defining an larticle receiving void therein, the base panel having outer edges in outwardly spaced relation from said interior edge and in contacting relation to the container inner Wall sur-y faces partially spacing ythe article from the said side walls, integral spacer walls foldably connected to said 'base panel outer edges and disposed in overlying relation to marginal edge portions of said base panel intervening the points of contact with the article and side walls of the container, the spacer walls being comprised of spacer panels foldably connected and disposed in mutual atwise relation and in vertical disposition to the base panel, projections from said interior edge adjacent the spacer walls folded in atwise contacting relation to the interior surface of the spacer walls and in combination therewith providing multiple ply continuous lateral spacer means in atwise vertical relation and parallel to the container side walls `and disposed between the container side Walls and the article, integral separable top spacer means in spaced relation to the base panel and integrally and foldably connected to two of said interior edge projections, the top spacer means in contacting relation with and disposed between the end of the article in the container and the top closure and effectively spacing the same 4and positioning the spacer insert in relation to the article.

2. The spacer insert claimed and described in claim 1, wherein the separable top spacer means comprises a spacer bar having integral panel portions, said panel portions olded to form a greater thickness than the unitary Iblank `fnom which the spacer insert is formed.

References Cited in the tile of this patent UNITED STATES PATENTS Kohlhaas May 17, 

1. IN A CONTAINER HAVING VERTICAL WALLS IN POLYGONAL FORMATION AND A TOP CLOSURE ENCLOSING AN ARTICLE OF MANUFACTURE, A SPACER INSERT FOR POSITIONING OVER AND IN CIRCUMFERENTIAL ENGAGEMENT WITH THE ARTICLE TO LATERALLY SPACE THE ARICLE FROM THE VERTICAL SIDE WALLS OF THE CONTAINER, SAID INSERT COMPRISING A UNITARY BLANK HAVING A BASE PANEL HORIZONTALLY DISPOSED ABOUT A TRANSVERSE SECTION OF THE SAID ARTICLE AND HAVING AN INTERIOR EDGE DEFINING AN ARTICLE RECEIVING VOID THEREIN, THE BASE PANEL HAVING OUTER EDGES IN OUTWARDLY SPACED RELATION FROM SAID INTERIOR EDGE AND IN CONTACTING RELATION TO THE CONTAINER INNER WALL SURFACES PARTIALLY SPACING THE ARTICLE FROM THE SAID SIDE WALLS, INTEGRAL SPACER WALLS FOLDABLY CONNECTED TO SAID BASE PANEL OUTER EDGES AND DISPOSED IN OVERLYING RELATION TO MARGINAL EDGE PORTIONS OF SAID BASE PANEL INTERVENING THE POINTS OF CONTACT WITH THE ARTICLE AND SIDE WALLS OF THE CONTAINER, THE SPACER WALLS BEING COMPRISED OF SPACER PANELS, FOLD- 